Aerodynamic system and adjustable fairings

ABSTRACT

Embodiments provide an aerodynamic fairing system that may comprise a base configured to mount to a vehicle, an arm coupled to the base at a proximate end and extending laterally, and a fairing mounted to the arm having an inboard and an outboard surface. The fairing outboard surface may provide an aerodynamic outer surface to direct flow to an angle to the rear. The arm may a fixed or adjustable length arm. The arm may provide a mounting area for a mud flap such that aerodynamic system may act as a mud flap hanger. Embodiments also provide an adjustable mud flap hanger.

RELATED APPLICATIONS

This patent application is a continuation of U.S. patent applicationSer. No. 16/018,413, filed Jun. 26, 2018, entitled “AERODYNAMIC SYSTEMAND ADJUSTABLE FAIRINGS,” is a continuation of U.S. patent applicationSer. No. 15/491,477, filed Apr. 19, 2017, entitled “AERODYNAMIC SYSTEMAND ADJUSTABLE FAIRINGS,” which is a continuation of U.S. patentapplication Ser. No. 14/666,019, filed Mar. 23, 2015, entitled“AERODYNAMIC SYSTEM AND ADJUSTABLE FAIRINGS,” now U.S. Pat. No.9,663,157, which is a continuation of U.S. patent application Ser. No.14/070,294, filed Nov. 1, 2013, entitled “AERODYNAMIC SYSTEM ANDADJUSTABLE FAIRINGS”, now U.S. Pat. No. 9,027,983, which claims priorityunder 35 U.S.C. 119(e) to U.S. Provisional Patent Application No.61/721,314, filed Nov. 1, 2012, entitled “ADJUSTABLE MUD FLAP HANGERWITH DURABLE AERODYNAMIC FAIRING ATTACHMENT,” and U.S. ProvisionalPatent Application No. 61/746,386, filed Dec. 27, 2012, entitled“AERODYNAMIC SYSTEM AND ADJUSTABLE FAIRINGS,” by Joshua Butler, KyleWalker, Redza Shah and Timothy Uys, all of which are fully incorporatedby reference herein in their entireties.

TECHNICAL FIELD

This disclosure relates to aerodynamic systems for vehicles. Moreparticularly, this disclosure relates to aerodynamic fairings forvehicles. Even more particularly, embodiments relate to aerodynamicfairings and support arms for large vehicles such as tractor trailers.

BACKGROUND

Large vehicles such as semis may easily travel several thousand mileseach month, including on highways and other routes which allow forhigher speeds. Poor aerodynamics cause a decrease in fuel economy and anincrease in operating cost. Therefore, there is a need to increase theaerodynamics of such vehicles.

SUMMARY OF THE DISCLOSURE

Embodiments described herein provide systems and methods for improvingthe aerodynamics of vehicles, including large vehicles that are commonlyseen pulling cargo trailers on highways, and which are generallyreferred to as “semis,” “18-wheelers,” “tractor trailers,” and the like.Embodiments may also be beneficial on other vehicles as well.

One embodiment includes a fairing assembly adapted to couple to avehicle, the assembly comprising an arm comprising one or more mud flapmounts to mount a mud flap and a fairing coupled to the arm, the fairingpositioned to be to an outboard side of the mud flap, the fairing havingan inboard surface and an outboard surface, the fairing outboard surfacecomprising an aerodynamic outer surface to direct flow in a rearwardangle, including, but not limited to rearward and downward, rearward andupward, rearward and outward, rearward and inward and combinationsthereof.

The fairing assembly may further comprise an adapter coupled to thefairing and to the arm at a distal end of the arm. The adapter can beconfigured such that the fairing is mountable in a plurality of mountingpositions. According to one embodiment, the fairing may mount in aplurality of vertical, horizontal or rotational positions. According toone embodiment, the adapter comprises an adapter plate that defines aset of adapter mounting holes and a set of fairing mounting holes. Theset of adapter mounting holes can align with a set of end holes at theend of the mud flap hanger arm in one or more positions and the fairingmounting holes can align with a set of fairing holes defined in thefairing. One embodiment may comprise a second plate coupled to the mudflap hanger arm, where the set of adapter mounting holes align with aset of holes in the second plate in one or more positions.

Furthermore, one embodiment of the arm can comprise a first anchormember, a second anchor member and a spring coupled to the first anchormember and the second anchor member. The spring can bias the arm to abase such that the arm is deflectable relative to the base. In anotherexample, the spring biases an adapter plate to the arm such that thefairing is deflectable relative to the arm. In another embodiment, oneor more springs may couple to the base and adapter plate to bias boththe base and adapter plate.

The arm may comprise an adjustable length sleeve further comprising amain body defining an inner portion receiving channel and a first set ofpositioning holes. The adjustable sleeve may also comprise an innerportion at least partially received in the inner portion receivingchannel. The inner portion may define a second set of positioning holes.The arm may further comprise an anchor member extending across and outof the inner portion. The main body can define a slot to accommodate theanchor member.

Another embodiment provides a fairing assembly adapted to position afairing behind a wheel of a vehicle having a set of wheels, the fairingassembly comprising, a base configured to mount to the frame rail of thevehicle, an arm coupled to the base at a proximate end and extendinglaterally, an adapter at a distal end of the arm and a fairingconfigured to be located behind a wheel. By way of example, the fairingcan be located between the wheels of a tandem set of wheels, behind arear wheel of a tandem set of wheels or located behind another wheel.The fairing can be coupled to the adapter in a mounting positionselected from one or more mounting positions.

The fairing can comprise a leading edge and a trailing edge. At leastone of the fairing leading or trailing edges can have a shapesubstantially corresponding to a wheel shape. The fairing may also havean inboard surface and an outboard surface. The fairing outboard surfacecomprising an aerodynamic outer surface to direct flow in a rearwardangle.

According to one embodiment, the base comprises a first anchor memberand the arm comprises a second anchor member. A spring is coupled to thefirst anchor member and the second anchor member. The spring couples thearm to the base through tension such that the arm is deflectablerelative to the base. In one embodiment, the fairing may also be springattached such that the fairing is deflectable relative to the arm.

The fairing may have an aerodynamic outboard surface to direct flow in adesired manner. According to one embodiment, the outer surface maydirect flow in a rearward angle such as straight back, back and out orback and in.

Another embodiment can comprise a mud flap hanger arm that includes asleeve comprising a main body defining an inner portion receivingchannel and having a mud flap mounting member defining a set of spacedmud flap mounts. The sleeve can further include an inner portion atleast partially received in the inner portion receiving channel. Theinner portion can be translatable in the inner portion receiving channelto a plurality of positions. A locking mechanism can be configured tolock the relative position of the main body and inner portion. A basecan be coupled to the sleeve.

Another embodiment can include an aerodynamic system for a vehicle. Thesystem can comprise a first fairing assembly having a first arm coupledto the vehicle and a fairing coupled to an outboard end of the firstarm, the fairing having an outer surface to direct airflow leaving awheel in a first rearward angle. The system can further comprise one ormore additional aerodynamic components acting in cooperation with thefairing assembly to reduce drag of the vehicle about the wheel,including for example, aerodynamic wheel covers, quarter fender panels,middle fairings. According to one embodiment, the first fairing assemblycomprises a mud flap fairing assembly and the one or more additionalaerodynamic components comprise a middle fender assembly. The middlefairing assembly may further comprise a second arm coupled to thevehicle between a forward set of wheels and the rear set of wheels ofthe tandem set of wheels and a middle fairing mounted to the second arm,the middle fairing having an outboard surface to direct airflow in asecond rearward angle.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure and theadvantages thereof, reference is now made to the following descriptiontaken in conjunction with the accompanying drawings in which likereference numerals indicate like features and wherein:

FIG. 1 depicts one embodiment of a mud flap hanger fairing assembly;

FIGS. 2A-2C depict views of one embodiment of an inner portion of afairing support arm;

FIGS. 3A-3B depict views of one embodiment of an outer sleeve of afairing support arm;

FIGS. 4A-4C depict views of one embodiment of a base;

FIGS. 5A-5B depict views of another embodiment of an inner portion of afairing support sleeve;

FIG. 6 depicts views of another embodiment of a mud flap hanger fairingassembly;

FIG. 7 depicts another embodiment of an inner portion of a fairingsupport arm;

FIGS. 8A-8B depict a partial view of one embodiment of support armillustrating deflection of an arm;

FIGS. 9A-9B depict a partial view of one embodiment of a support armillustrating selectable connection member spacing;

FIG. 10 depicts a view of another embodiment of a mud flap hangerfairing assembly;

FIG. 11 depicts a view of another embodiment of a mud flap hangerfairing assembly;

FIGS. 12A-12C depict views of one embodiment of a fairing;

FIGS. 13A-13B depict views of one embodiment of a mounting bracket;

FIG. 14 depicts a view of another embodiment of a mud flap hangerfairing assembly;

FIG. 15 depicts a view of another embodiment of a mud flap hangerfairing assembly;

FIG. 16 depicts a view of another embodiment of a mud flap hangerfairing assembly;

FIG. 17 depicts a view of another embodiment of a mud flap hangerfairing assembly;

FIG. 18 depicts a view of another embodiment of a mounting bracket;

FIG. 19 depicts a view of another embodiment of a mud flap hangerfairing assembly;

FIG. 20 depicts another embodiment of a mounting bracket;

FIG. 21 depicts one embodiment of a fairing mounted to a support arm;

FIG. 22 depicts one embodiment of a support member;

FIG. 23 depicts one embodiment of a support member and fairing;

FIGS. 24A-24B depict another embodiment of a mud flap hanger fairingassembly;

FIG. 25 depicts one embodiment of a fairing support arm;

FIG. 26 depicts another embodiment of a fairing support arm;

FIG. 27 depicts yet another embodiment of a fairing support arm;

FIG. 28 depicts yet another embodiment of a mud flap hanger fairingsupport assembly;

FIG. 29 depicts yet another embodiment of a mud flap hanger fairingsupport assembly;

FIG. 30 depicts a view of a mud flap hanger fairing mounted to a tractortrailer;

FIGS. 31A-31C depict views of positioning a mud flap hanger fairing;

FIG. 32 depicts a view of positioning another embodiment of a mud flaphanger fairing;

FIG. 33 depicts a view of positioning yet another embodiment of a mudflap hanger fairing;

FIGS. 34A-34C depict views of a middle fairing assembly;

FIG. 35 depicts a view of a middle fairing assembly coupled to a framerail;

FIGS. 36A-36B depict a view of a middle fairing base bracket;

FIG. 37 depicts a view of a mounting plate;

FIG. 38 depicts a view of another embodiment of a middle fairingassembly;

FIG. 39 depicts a view of another embodiment of a middle fairing supportarm;

FIG. 40 depicts a view of another embodiment of a middle fairing supportarm;

FIGS. 41A-41D depict views of another embodiment of a middle fairingsupport arm;

FIGS. 42A-42C depict views of another embodiment of a fairing supportassembly;

FIGS. 43A-43B depict simulations of air flow;

FIG. 44 depicts a view of an aerodynamic system;

FIG. 45 provides test results of testing an aerodynamic system;

FIG. 46 depicts a view of another embodiment of an aerodynamic system;

FIG. 47 depicts a view of another embodiment of an aerodynamic system.

DETAILED DESCRIPTION

The disclosure and various features and advantageous details thereof areexplained more fully with reference to the exemplary, and thereforenon-limiting, embodiments illustrated in the accompanying drawings anddetailed in the following description. Descriptions of known startingmaterials and processes may be omitted so as not to unnecessarilyobscure the disclosure in detail. It should be understood, however, thatthe detailed description and the specific examples, while indicating thepreferred embodiments, are given by way of illustration only and not byway of limitation. Various substitutions, modifications, additionsand/or rearrangements within the spirit and/or scope of the underlyinginventive concept will become apparent to those skilled in the art fromthis disclosure.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a process,product, article, or apparatus that comprises a list of elements is notnecessarily limited to only those elements but may include otherelements not expressly listed or inherent to such process, product,article, or apparatus. Further, unless expressly stated to the contrary,“or” refers to an inclusive or and not to an exclusive or. For example,a condition A or B is satisfied by any one of the following: A is true(or present) and B is false (or not present), A is false (or notpresent) and B is true (or present), and both A and B are true (orpresent).

Additionally, any examples or illustrations given herein are not to beregarded in any way as restrictions on, limits to, or expressdefinitions of, any term or terms with which they are utilized. Insteadthese examples or illustrations are to be regarded as being describedwith respect to one particular embodiment and as illustrative only.Those of ordinary skill in the art will appreciate that any term orterms with which these examples or illustrations are utilized encompassother embodiments as well as implementations and adaptations thereofwhich may or may not be given therewith or elsewhere in thespecification and all such embodiments are intended to be includedwithin the scope of that term or terms. Language designating suchnon-limiting examples and illustrations includes, but is not limited to:“for example,” “for instance,” “e.g.,” “in one embodiment,” and thelike. Furthermore, any dimensions, materials or other suchcharacteristics are provided by way of example and not limitation.

Embodiments described herein provide systems and methods for improvingthe aerodynamics of vehicles, including large vehicles that are commonlyseen pulling cargo trailers on highways, and which are generallyreferred to as “semis”, 18-wheelers,” “tractor trailers” and the likeand may be beneficial on other vehicles as well. Embodiments may beparticularly suited for reducing drag, reducing or otherwise controllingthe generation or distribution of spray/splash or improving thestability of large vehicles in an airstream.

One embodiment comprises a support arm that couples to a vehicle on aproximate end and supports a fairing on a distal end. Embodiments of anarm may use a spring or other attachment to allow deflection of afairing assembly. Deflection of the fairing assembly may allow a personto access components behind the assembly, and may also absorb energyfrom tire blowouts, impacts or other debris. According to oneembodiment, the arm may use a two-sided spring attachment to also allowdeflection of a fairing in relation to the arm. In another embodiment,the arm may be fixed at the vehicle end, but the fairing adapter may bespring mounted to allow the fairing to deflect relative the arm.Multiple hangers having spring attachments having one-sided (vehicleside or fairing side) or two-sided spring attachments may be used tomount multiple fairings or to support a single larger fairing. In somecases, some fairings may be coupled to arms having spring attachmentswhile others are coupled arms that are fixed or a single fairing may becoupled to one or more arms having spring attachments and to one or morefixed arms. Multiple fairings may also be coupled to the same arm (e.g.,inboard and outboard of a mud flap or elsewhere).

According to one embodiment, a fairing support arm may have anadjustable length. Embodiments of an adjustable length hanger may allowthe hanger length to be set in any desired range, depending on vehicle.By way of example, but not limitation, for some semi-trucks, the rangeof an arm's extension preferably includes lengths between 25 inches and33 inches within the range of extension. However, the range of extensionof arms may be selected as needed or desired and may, in some cases, notinclude lengths between 25 inches and 33 inches (e.g., an arm may have arange of extension that terminates at less than 25 inches, an arm mayhave a range of extension that begins at greater than 34 inches, etc.).Adjustable and fixed length arms as well as spring attached and fixedarms may have a variety of form factors. In some embodiments the armsmay be straight. In others, the arms may be angled at the end (e.g.,“shorty” hangers).

A support arm may mount to a vehicle frame in a manner that allows theposition of the arm to be selectable. According to one embodiment, anassembly base may include a connection system that accommodates varioushole patterns in a frame rail or other portion of a vehicle so that thebase may be used with different hole configurations. In anotherembodiment, the base may include an adapter that allows the base to bemounted in one or more positions or rotational orientations.

In one embodiment, the arm may be a mud flap hanger arm. A fairing maymount to the mud flap hanger and be positioned outboard of the mud flap.In other embodiments, a fairing may be integral with a mud flap.Embodiments may also include a middle fairing hanger arm and middlefairing. The middle fairing hanger may have an adjustable length toaccommodate various tire sizes and configurations, and may bedeflectable as well. In some embodiments, the hanger is deflectable onlyin a generally vertical plane to prevent contact with a tire.

The fairing may be mounted to the end of the arm using an adapter thatis coupled to or integral with the arm. According to one embodiment, theadapter may allow the horizontal, vertical or rotational position of thefairing to be selected. According to one embodiment, the adapter mayinclude an adapter plate and a second plate. The second plate may be anend plate of an arm, a plate, a fixed or other plate coupled to astandard mud flap hanger or other hanger. The adapter plate may becoupled to the second plate in a number of selectable positions toadjust the mounting position of the fairing.

According to one embodiment, the adapter may have an extension that canbe secured to a mud flap hanger using at least one of the existing holesin the hanger that are normally used to attach a mud flap to the hangerwith fasteners such as a nut and bolt. By using a longer fastener, forexample, this mounting method does not prevent the mud flap frommounting to the hanger using the same holes.

The fairing is preferably manufactured of durable material, such aspolyurethane, which can absorb frequent impacts and deflections of thematerial (e.g., the corner of the mud flap hangers are commonly hit whenbacking up, and mud flaps are frequently in contact with curbs).Preferred materials for manufacturing a fairing include plastics,metals, and composites. A deflectable, resilient, and wearable materialsuch as TPO or polyurethane may be desired, especially for regions ofthe part that may contact a trailer, ground, or wheels. Some materialsor manufacturing processes that may provide a part with a lower density,such as low density polyurethane, blow-molding, or rotational molding,for example, may be desired such that the part is less likely to causeadditional damage if it is damaged or dislodged from the vehicle, forexample.

In some embodiments, a fairing may be provided with mechanisms forcontrolling splash and spray while also reducing aerodynamic drag (forexample, perforations, fluid atomizing features, fluid flow directingfeatures such as ribs, fluid trapping or re-directing features, etc.). Afairing may be formed as a single body or it may be assembled, such aswith a structural center portion for support with deflectable materialattached to the outer edges of the center portion.

According to one embodiment the fairing may have a variety of shapes.For example leading edge of the fairing may be straight or curved andthe outer surface of the fairing may flat, angled or curved outward,angled or curved inward or some combination thereof to promote desiredaerodynamic flow. The fairing may have symmetric design to fit eitherside of the vehicle in a desired position, including positions that areangled inward or outward.

One aspect of an aerodynamic system can include fairing assemblies thatcan be advantageous for improving the aerodynamic efficiency of largevehicles by helping to direct air flow around the wheels. Embodimentsmay utilize a fairing to direct airflow around selected components,including wheels, brake assemblies, and other components as needed.Fairings may be used in combination and with other aerodynamic products.For example, one or more of a rear mud flap fairing, a middle fairing,aerodynamic wheel covers and an aerodynamic quarter fender panel may beused together to increase aerodynamic efficiency.

Another embodiment can include an adjustable length mud flap hanger armwith or without a fairing.

FIG. 1 depicts view of one embodiment of a mud flap fairing assembly 100comprising an arm 110 that attaches to a vehicle at a proximate end(“proximate” used to refer to being closer the vehicle) and supports afairing 105 at a distal end (“distal” used to refer to being furtheraway from the vehicle). Arm 110 may also provide mud flap mountingmembers having spaced slots to allow mounting of a mud flap suspendedbelow arm 110. The fairing may mount to arm 110 using an adapter such asmounting adapter plate 180, various embodiments of which are discussedbelow. The adapter can allow the fairing to mount in various mountingpositions to adjust the horizontal, vertical or rotation of the fairing.

Arm 110 couples to vehicle at a base 130 that couples to the frame ofthe vehicle (or other support structure) and connects to the vehicle (orother support structure) using one or more connection members 132(bolts, rivets, screws or other connection member), welding or othercoupling mechanism. Arm 110 may be rotatable relative to base 130 aboutone or more axes of rotation to enable arm 110 to deflect relative tothe vehicle frame. Arm 110 may be straight along its entire length orarm 110 may be curved or angled. In some embodiments, arm 110 is curvedor angled such that fairing 105 is supported more closely to its midlineor center of mass of fairing 105.

Arm 110 may also be adjustable to extend some lateral length Las neededto position fairing 105 relative to the wheels of the vehicle. To thisend, arm 110 may be telescoping, having multiple portions that can slideinto each other to allow adjustability, such as inner portion 117translatable within an outer sleeve 119. While only two portions areillustrated, arm 110 may include additional telescoping portions andinclude other arrangements. By way of example, but not limitation, therelative positions of sleeve 119 and inner portion 117 may be reversedsuch that the sleeve mounts to the vehicle and the fairing 105 mounts tothe inner portion. A locking mechanism such as a bolt or other mechanismmay be used to lock the positions of the telescoping portions to achievea desired length of arm 110. Other mechanisms may be used to adjust thelength of the arm in addition to or in lieu of telescoping including,but not limited to, spacers at the end proximate to the vehicle whichoffset the arm from the vehicle or spacers at the distal end of the armthat further offset the fairing from arm and hence the vehicle.

Fairing 105 has an inboard side 155 and an outboard surface 145. Ingeneral, fairing 105 may have a generally thin lateral profile and amuch larger longitudinal profile, providing a surface area to promotestreaming. Outboard surface 145 may form an aerodynamic outer surfacethat provides attached flow for longitudinal air flow (air flowstreaming back as the vehicle moves forward) and can direct flow in alongitudinal angle such as parallel to the longitudinal axis of thevehicle, primarily back and inwards or back and outwards. Preferably,the fairing has a sufficient projected surface area (in view from theside of the vehicle) to promote attached flow. By way of example, butnot limitation, the projected surface area may be 10 in2 to 10 ft2,though smaller and larger projected surface areas may be used if neededor desired.

Inner portion 117 and outer sleeve 119 may have a variety of formfactors. FIGS. 2A-2C, for example, are views of one embodiment an innerportion 117. As depicted in FIGS. 2A-2C, inner portion 117 may comprisean inner portion main body 200 formed of a material, such as steel orother material. Main body may form an inner channel 207 running all or aportion of the distance from the proximate end of inner portion 117 tothe distal end of inner portion 117. Channel 207 can accommodate aspring or other components as discussed below. According to oneembodiment, channel 207 may be open on one side (e.g., the bottom orother side) to allow access to components in channel 207. In otherembodiments, channel 207 is not fully open on any of the top, bottom,front or back.

Main body 200 may have a pattern of length selection holes 205 definedtherein that correspond to length selection holes in the outer sleeve.Holes 205 may be offset from the centerline of inner portion 117 or beotherwise arranged. In general, the pattern of holes may, in conjunctionwith holes on the outer sleeve, allow the inner and outer portions to belocked in a relative position using a bolt or other cross-member.

According to one embodiment, main body 200 may be formed by folding asheet of metal along multiple lines. In some embodiments, steel or othermaterial may be used. In other embodiments, main body 200 may be formedfrom multiple pieces and types of materials coupled together.

Inner portion 117 may further include a distal end plate 210 havingopening 211 at the proximate end of channel 207. End plate 210 may becoupled to main body 200 by welding or other coupling mechanism andpartially cover the distal portion of channel 207. Opening 211 passesthrough end plate 210 and may accommodate a component, such as an eyebolt, a partial U-bolt or other component.

Inner portion 117 may also include a proximate end plate 215 welded orotherwise joined main body 200 that at least partially covers theproximate end of channel 207. End plate 215 may include an opening 217there through to allow a component to pass through end plate 215 intochannel 207. In some embodiments, end plates 210 and 215 may be formedfrom the same material main body 200 or of different materials. Endplates 210 and 215 may provide additional rigidity to inner portion 117.End plates 210 and 215 may be flush with or inset slightly from the endsof main body 200 and include edge flanges that promote welding or otherjoining at 219.

FIGS. 3A-3B depict views of one embodiment of a sleeve 119. In someembodiments, sleeve 119 may comprise a main body 300 formed from asingle sheet of material, such as steel or other material, that is bent,curved or angled into a desired configuration. In other embodiments,main body 300 may be formed multiple pieces and materials. Sleeve mainbody 300 may include an inner portion receiving portion 302 that definesa channel 304 into which an inner portion may be inserted (e.g., innerportion 117 of FIGS. 2A-2C or other inner portion). Channel 304 may havea profile that generally matches the outer profile of the inner portion.A pattern of length selection holes 305 may be defined through the frontand back faces of main body 300 that are spaced so that the holes matchcorresponding holes in the inner portion (e.g., pattern of holes 205illustrated in FIG. 2A). A through bolt passing the length selectionholes or other securing mechanism can be used to secure the relativepositions of sleeve 119 and the inner portion received in receivingchannel 304.

Sleeve 119 may further include a mud flap mounting members 306 thatcomprises portions of material extending downward from main body 300 andthat define a set of horizontally spaced slots 311. According to oneembodiment, mud flap mounting members 306 comprise flanges that run allor a portion of the length of main body 300. The mud flap mounting arearuns a sufficient lateral distance to allow a standard mud flap to besecurely mounted. A benefit of an adjustable length hanger may be thatmud flaps may not require trimming if one desires the flap not to stickout past the wheels, for example. Trimming of mud flaps is commonly doneto improve aerodynamic efficiency but the process requires substantialtime and effort.

Furthermore, FIG. 3A depicts end plate 310 having end holes 312. Endplate 310 may be welded or otherwise joined to main body 300 to providea fixed plate. According to one embodiment, end plate is inset from theends of main body 300 and includes flanges to promote welding or joining(e.g., at 315). In one embodiment, end holes 312 are not threaded, butend plate 310 may comprise threaded nuts coupled to the proximate sideof end plate 310, such as by welding or other mechanism, to create athreaded hole. Holes 312 provide for outward attachment of a fairingadapter, a fairing or other components. As one example, an adjustableadapter plate 180 (see FIG. 1) may be configured to mount to fixed endplate 310 in multiple positions. Adapter plate 180 can be configured toallow mud flap mounting members 306 to deflect elastically to secure amud flap even when adapter plate 180 is installed.

Returning briefly to FIG. 1, arm 110 may deflect by one or more ofrotation and translation relative to the trailer frame, such as inresponse to a tire blowing out, impact of the hanger assembly with anobject, a mechanic pushing arm 110 to gain access to a component, etc.According to one embodiment, arm 110 may deflect because arm 110 is notrigidly attached to base 130, but is held against base 130 by springtension.

FIGS. 4A-4C depict views of one embodiment of base 130. Base 130 cancomprise a base plate 400, an anchor member 405 and connection members415. Base plate 400 can include a first portion 420 configured to mountto the vehicle. For example, first portion 420 may be flat to restagainst the frame of a vehicle. Second portions 425 may be angled frontand rear flanges angled outwards a selected angle away from the vehicleto limit deflection as discussed below. By way of example, but notlimitation, base plate 400 may be formed of single sheet of material,such as steel or other material, bent along selected lines. In otherembodiments, base plate 400 may be formed of one or more pieces made ofthe same or different materials.

According to one embodiment, anchor member 405 is coupled to base plate400, e.g., by welding or otherwise (represented at weld 417). Anchormember is any member that can provide a suitable attachment point for atension member, such as a spring. The tension member may be coupled toanchor member 405 directly or through a linkage, such as chain 430.

Connection members 415 can be used to bolt or otherwise connect base 130to the vehicle. In the embodiment illustrated, anchor member 405 andconnection members 415 comprise portions of a U-bolt. In otherembodiments, anchor member 405 and connection members 415 may compriseportions of an eye bolt or other anchor. In yet another embodiment,anchor member 405 and connection member 415 may be separate components(e.g., anchor member may be loop welded or otherwise attached to baseplate 400 and connection member 415 may be threaded posts). As anotherexample, one connection member may be the threaded post of a partialU-bolt or eye bolt and the other anchor member a threaded stud. A basemay be connected to the vehicle using other types of connection members(e.g., screws, rivets, etc.) or connection mechanisms (e.g., welding orother joining technique).

Base plate 400 provides openings for connection members 415. Connectionmembers 415 may be advanced through the openings in mud flap hanger baseplate 400 for coupling base 130 to a vehicle frame. In some embodiments,the spacing between the openings may be based on frame hole spacing,typically 1 and ⅛ inches or other spacing. Members 415 may be threadedinto, welded to or otherwise coupled to base plate 400. Base plate 400may further include openings 435 to accommodate other connectionmembers, such as bolts or other connection members that may be used toconnect base plate 400 to the vehicle.

FIGS. 5A-5B depict an embodiment of an inner portion 117 mounted to abase 530. Base 530 may be similar to that discussed above except thatbase plate includes front and back angled flanges 534 and top and bottomangle flanges 532. Furthermore, additional support is provided to innerportion 117. A support may include an end plate 505 and a buttress 510coupled to the bottom of inner portion 117 and the outboard face of endplate 505. Buttress 510 can provide additional distribution of forcebetween inner portion 117 and base 530 to provide additional verticalsupport to inner portion 117. Inner portion 117 may be welded orotherwise joined to end plate 505 and buttress 510.

At a proximate end, an anchor member may pass through an opening of anendplate (e.g., anchor member 405 of FIG. 4A can pass through opening217 as illustrated in FIG. 2B). At the distal end, a second anchormember 565 may extend inward from end plate 210. Second anchor member565 may be a U-bolt, eye bolt, a U of material or other component thatcan serve as an anchor point. According to one embodiment, for example,anchor member 565 is an eye bolt threaded through a hole (e.g., hole 211of FIG. 2A), with the eye of the bolt on the proximate side of distalplate 210 and nuts 575 on the distal side.

A first end of spring 560 (or other tension member) is hooked orotherwise attached to chain 555, which is attached to the anchor memberof base 530 (e.g., similar to as illustrated in FIG. 4A for base 130)and a second end of spring 560 is hooked or otherwise attached to secondanchor member 565 to hold inner portion 117 against base 530 based onthe tension force. Because spring 560 can stretch, inner portion 117 candeflect vertically and horizontally when sufficient force is applied.Consequently, the arm may deflect.

As the force is removed, the spring force may act as a return mechanismsuch that inner portion 117 is returned to a preferred (or neutral)position. The deflection inner portion 117 relative to base 130 may becontrolled. For example, the size and angle of front and back flanges534 may control forward and backward deflection to a selected angle andupper and lower flanges 532 may control vertical deflection to aselected angle. It can be noted that each flange may angle the sameamount or different amounts and the angle of deflection may be limitedto the same angle in each direction or different angles in eachdirection or the same angle in some directions and different angles inother directions.

As depicted in FIG. 5B, in some embodiments, second anchor member 565may be an eye bolt passing through end plate 210 of inner portion 117(e.g., through an opening such as opening 211 depicted in FIG. 2A). Theeye bolt may be advanced or withdrawn to adjust how much tension isapplied to spring 560, thereby dictating how much force is needed todeflect an arm (e.g., arm 110 of FIG. 1) relative to the vehicle frame.Fasteners, such as nuts 575, may be used to secure the anchor member ina desired position. One advantage of the embodiment of FIG. 5B is thatthe spring can be tensioned from external to the inner portion 117 byrotating the nuts 575 to advance the threaded anchor member 565. Thisallows the spring to be easily tensioned after installation of innerportion 117 to control the amount of force required to deflect the arm.Additionally, the spring can be easily loosened to make the arm moredeflectable (e.g., during maintenance).

FIG. 6 depicts views of another embodiment of a rear mud flap fairingassembly 600 comprising an arm 610 that attaches to a vehicle at aproximate end and supports a fairing 105 at a distal end. Arm 610 mayalso provide support for a mud flap 635 suspended below arm. Fairing 105may mount to the distal end of arm 610 using an adapter plate 180.

Arm 610 couples to vehicle at a base 630 that connects to the vehicleusing one or more connection members 632, welding or other couplingmechanism. Arm 610 may be rotatable relative to base 630 about one ormore axes of rotation to enable arm 610 to deflect relative to thevehicle frame. Arm 610 may be straight along its entire length or arm610 may be curved or angled. In some embodiments, arm 610 being curvedor angled such that fairing 105 is supported more closely to its midlineor center of mass of fairing 105.

Arm 610 may also be adjustable to extend some length L as needed toposition fairing 105 relative to the wheels of the vehicle. To this end,arm 610 may be telescoping, having multiple portions that can slide intoeach other to allow adjustability. Accordingly, according to oneembodiment, arm 610 may comprise an inner portion 617 translatablewithin an outer sleeve 619. While only two portions are illustrated, arm610 may include additional telescoping portions and include otherarrangements. By way of example, but not limitation, the relativepositions of sleeve 619 and inner portion 617 may be reversed such thatthe sleeve mounts to the vehicle and the fairing 105 mounts to the innerportion. A locking mechanism such as bolts 650 or other mechanism may beused to lock the positions of the telescoping portions to achieve adesired length of arm 610.

In some embodiments, sleeve 619 may comprise a main body formed from asingle sheet of material, such as steel or other material that is bent,curved or angled into a desired configuration. In other embodiments, themain body may be formed multiple pieces and materials. The sleeve mainbody may include a receiving portion that defines a channel into whichan inner portion 617 may be inserted. The channel may have a profilethat generally matches the outer profile of the inner portion 617. Apattern of length selection holes may be defined through the front andback faces of the sleeve main that are spaced so that the holes matchcorresponding length selection holes in the inner portion 617. A throughbolt 650 passing through the holes or other securing mechanism can beused to secure the relative positions of sleeve 619 and the innerportion 617.

Sleeve 619 may further include a mud flap hanger members 664 thatcomprises portions of material extending downward at the lower portionof the main body and that define a set of horizontally spaced mud flapmounting slots 668. Mud flap hanger members may run a sufficienthorizontal distance to allow a mud flap to be mounted at multiplepoints.

Sleeve 619 may further define a lateral slot 640 to accommodate ananchor member 645 passing through inner portion 617. Slot 640 allows arm610 to accommodate anchor member 645 when sleeve 619 and inner portion617 are in a variety of relative positions. Thus, arm 610 may be similarto arm 110 except that sleeve 619 accommodates the through bolt.

A fairing may be directly coupled to an arm or may be coupled to an armusing an adapter. Suitable adapters may be provided to mount a fairingto a variety of arms, including conventional mud flap hanger arms thatare not otherwise configured to support a fairing.

FIG. 6 depicts one embodiment of fairing 105 mounted to arm 610 with anadapter that comprises mounting adapter plate 180. Adapter plate 180 maymount to the end of arm 610 to have a generally longitudinally alignedouter surface and inner surface. Adapter plate 180 may comprise apattern of fairing mounting holes to match holes in the fairing 105 andpattern of adapter mounting holes to match a pattern of end holesdefined in a distal face of arm 610. Referring briefly to FIG. 3A andFIG. 12, the pattern of adapter mounting holes may match holes in theend of outer sleeve 619 (e.g., similar to holes 312 of FIG. 3) to allowadapter plate 180 to be mounted to the end of an arm and the pattern offairing mounting holes may match fairing holes 1203 to allow a fairing105 to be mounted on adapter plate 180 using connection members 185,such as bolts or other connection members. The pattern of holes onadapter plate 180 can be configured to allow the bracket to be mountedin various horizontal, vertical or rotational positions relative to thearm and hence the fairing to be mounted in various positions so that thevertical, horizontal and angle of rotation of the fairing may beselected. Thus, an adjustable bracket may be couple to a fixed end plate(e.g., end plate 310) to provide a mounting adapter for the fairing. Inother embodiments, the adapter plate may only provide a single mountingposition. In yet other embodiments, the fairing may mount directly toend plate 310 in a single or in multiple positions.

FIG. 7 depicts a view of one embodiment of an inner portion 617,illustrating an alternate return mechanism for allowing arm 610 todeflect relative to base 630 and to return to a preferred position.Inner portion 617 can comprise a main body 700 defining a channel 702sized to accommodate various components. A pattern of length selectionholes 705 may be defined through main body 700 that can correspond tolength selection holes in the outer sleeve to allow a securingmechanism, such as a through bolt, to pass through inner portion 617 andthe outer sleeve to lock inner portion 617 and the outer sleeve inpreferred relative positions such that the arm has a desired length.

A proximate end plate 724 may be coupled to inner portion 617 that atleast partially covers the proximate end of channel 702. An opening 722through end plate 724 can provide access to channel 702. Opening 722 canbe sized to allow various components to pass through opening 722. Frontand rear lateral extensions 725 may extend outward from end plate 724and be spaced to be wider than the outer walls of main body 700 andpreferably to abut the outer surfaces of main body 700. Bolts or otherconnecting members may be accommodated through holes in main body 700and front and rear lateral extensions 725 to couple end plate 724 tomain body 700. In another embodiment, lateral extensions may extend tothe inside of channel 702 to allow connection of end plate 724 to innerportion 617.

Base 630 may include a base plate 730 and an anchor member 735 coupledto base plate 730. Anchor member 735 may be an eye bolt, a U-bolt, au-shaped piece of metal or other member to which chain 745 or tensionmember can anchor. According to one embodiment, anchor member 735 is aU-bolt with a single post that passes through base plate 730 (a partialU-bolt). The post can act as a connection member to secure base 630 tothe vehicle. A second connection member 750, such as a threaded post,may be used to further secure base 630 to the vehicle frame. Thus, base630 may be bolted to frame rails.

A hook at the first end of spring 760 may connect to anchor member 645,which may be part of a through bolt 712 or other cross-member runningtransverse to channel 702. A hook at the second end of spring 760 mayconnect to chain 745 which, in turn, connects to anchor member 735.Spring 760 maintains tension on chain 745 coupling inner member 617 tobase 630 through tension. However, if sufficient force is asserted oninner member 617, inner member 617 may rotate relative to base 630. FIG.8A, for example, depicts inner portion 617 in a neutral position inwhich end plate 724 and the base plate 730 are generally parallel andabutting and FIG. 8B depicts lateral deflection of inner portion 617relative to base 630, such that end plate 724 is angled relative to thebase plate 730. For simplicity, FIG. 8B only depicts simple deflectionin a substantially horizontal plane. However, the deflection may occurin multiple planes or may include some rotation about an axis normal tothe vehicle frame rail, or some combination.

FIGS. 9A and 9B depict one embodiment of inner portion 617 and base 630illustrating various arrangements of connection members. In the exampleof FIGS. 9A and 9B, first connection member 905 may be the shank of aU-bolt or other bolt (e.g., extending from anchor member 735 throughbase plate 730 of FIG. 7), may be a fixed threaded post separate fromthe anchor member or may be another connection member, such as athreaded stud. Second connection member 750 is a threaded stud that canbe received in one of several spaced holes 915 through base plate 730.The selection of any opening 915 may be based on the openings aligningwith corresponding openings on the vehicle frame. The connection memberscan pass laterally through a vehicle frame and be secured with nuts.

FIGS. 10 and 11 depict views of one embodiment of a rear mud flapfairing assembly 1000 comprising an arm 1010 that attaches to a vehicleat a proximate end and supports a fairing 105 at a distal end. Fairing105 may be mounted to arm 1010 using an adapter 1080 that couples to thedistal end of sleeve 1019. One embodiment of adapter 1080 is discussedin more detail below in conjunction with FIGS. 13A and 13B.

Arm 1010 couples to vehicle at a base 1030 at the proximate end andconnects to the vehicle using one or more connection members 1032, suchas threaded shanks that attach with nuts or other connection members,welding or other coupling mechanism. Arm 1010 may be rotatable relativeto base 1030 about one or more axes of rotation to enable arm 1010 todeflect relative to the vehicle frame. Arm 1010 may be straight alongits entire length or arm 1010 may be curved or angled

Arm 1010 may also be adjusted to length L as needed to position fairing105 relative to the wheels of the vehicle. To this end, arm 1010 may betelescoping having multiple portions that can slide into each other toallow adjustability. Accordingly, according to one embodiment arm 1010may comprise an inner portion 1017 translatable within an outer sleeve1019. While only two portions are illustrated, arm 1010 may includeadditional telescoping portions and include other arrangements By way ofexample, but not limitation, the relative positions of sleeve 1019 andinner portion 1017 may be reversed such that the sleeve mounts to thevehicle and the fairing 105 mounts to the inner portion. A lockingmechanism such as bolt 1050 or other mechanism may be used to lock thepositions of the telescoping portions to achieve a desired length of arm1010.

In some embodiments, sleeve 1019 may comprise a main body formed from asingle sheet of material, such as steel or other material that is bent,curved or angled into a desired configuration. In other embodiments, themain body may be formed multiple pieces and materials. The sleeve mainbody may include an inner portion receiving portion 1062 that defines achannel into which an inner portion 1017 may be inserted. The channelmay have a profile that generally matches the outer profile of the innerportion 1017. In the example of FIGS. 10 and 11, the channel has agenerally circular shape. A pattern of holes may be defined through thefront and back faces of the sleeve main that are spaced so that theholes match corresponding holes in the inner portion 1017. A throughbolt 1050 passing the holes or other securing mechanism can be used tosecure the relative positions of sleeve 1019 and the inner portion 1017received in receiving channel.

Sleeve 1019 may further include mud flap mounting members 1064 thatcomprise portions of material extending downward at the lower portion ofthe main body and that define a set of horizontally spaced mud flapmounting slots 1068. Mud flap hanger members may run a sufficienthorizontal distance to allow a mud flap to be mounted at multiplepoints.

Sleeve 1019 may further define a slot 1040 to accommodate an anchormember 1045 passing through inner portion 1017. Slot 1040 allows arm1010 to accommodate anchor member 1045 when sleeve 1019 and innerportion 1017 are in a variety of relative positions. Anchor member 1045may be a bolt or other cross member that provides an anchor point for aspring as discussed above.

With reference to FIG. 11, base 1030 can include a base plate 1100,connection member 1032 and an anchor member 1110 coupled to base plate1100. Anchor member 1110 can extend through an opening in endplate 1015of inner portion 1017. A tension member comprising a chain 1020 andspring 1025 can be coupled between anchor member 1110 and a secondanchor member 1045 to create a tension force that holds inner portion1017 and base 1030 together. As discussed above, the spring allows innerportion 1017 to deflect and return to a neutral position.

Thus, as discussed above, mud flap fairing assemblies may includedeflectable arms having variable lengths in a variety of form factors.In other embodiments, the arms may be configured without mounting areasfor mud flaps so that the arms act as fairing supports but not mud flaphangers. In any case, fairing support arms may be placed in desiredlocations on the vehicle to support a variety of fairings.

As discussed above, fairing assemblies may include a fairing to directairflow. The shape, size, materials, stiffness, and othercharacteristics of a fairing may be selected to minimize splash/spray orprovide other advantages along with directing air flow. In someembodiments, a first fairing may be designated for use on the left sideof a vehicle and a second fairing may be designated for use on the rightside of the vehicle, such that fairings are manufactured asymmetricallyfor use on a particular side. For example, top and bottom edges maydiffer in one or more of shape, curvature, stiffness, etc. In otherembodiments, fairings may be symmetric or otherwise manufactured for useon either side of the vehicle.

FIGS. 12A-12C depict views of one embodiment of a fairing having aleading edge 1210, a trailing edge 1220, a top edge 1230 and a bottomedge 1240. The fairing may include a pattern of holes 1203 that allowmounting of the fairing. Leading edge 1210 has a curved portion foraccommodating the profile of a wheel. The fairing may be shaped to havea continuous aerodynamic surface from leading edge 1210 to trailing edge1220 to promote attached flow across the surface. According to oneembodiment, the fairing may be shaped to direct airflow over a firstsurface portion 1250, over a transition area 1260, over a second surfaceportion 1270 or some combination. In one embodiment, first surfaceportion 1250 may be formed as a relatively flat surface, transition area1260 may be formed as a discrete or stepped transition zonetransitioning from first surface portion 1250 to second surface portion1270, and second surface portion 1270 may be formed as an angled orcurved outward surface. The fairing may include more or fewer surfaces,areas or zones as needed and in some embodiments may have flat outersurfaces. Curves may be compound or simple, and stepped areas mayinclude more than one step.

The inner surface of the fairing may provide a flat mounting zone 1275that may abut and outboard face of an arm or adapter. An area ofincreased thickness 1280 may be disposed in front of the mounting zoneprovide additional support. The front face of area 1280 may be curved.

Fairing 105 and other fairings may be mounted to the end of support armsusing a variety of adapters, such as adapter 180, adapter 1080 and otheradapters. FIGS. 13A and 13B depict views of one embodiment of adapter1080 that may be used to mount a fairing. In particular, adapter may beused with existing mud flap hangers or other support arms. Adapter 1080may comprise an inboard fixed plate 1300 and an outboard adjustableplate 1305. The inner face of plate 1305 may face the outer face ofplate 1300. Adapter 1080 may also include a connector plate 1325.Connector plate 1325 may shaped to connect to the end of a hanger arm,such as arm 1010 of FIG. 10 or a conventional mud flap hanger throughwelding, bolts or other connection mechanism. Plate 1300 may beconnected to connector plate 1325 or otherwise coupled such that plate1300 is in a fixed orientation relative to the arm.

Fixed plate 1300 may include a first set of holes 1310. Adjustable plate1305 may include a pattern of plate mounting holes 1315 and a set offairing mounting holes 1320. Fairing mounting holes 1320 may beconfigured correspond with holes in a fairing. Plate mounting holes 1315may be configured so that multiple holes 1315 in adjustable plate 1305may align with multiple holes 1310 in fixed plate 1300 in variouspositions of rotation, or horizontal or vertical translation, allowingadjustable plate 1305 to be positioned and secured relative to firstplate 1300. Consequently, the fairing may be secured at a selected oneof several mounting positions relative the arm. In other embodiments,only a single mounting position is provided. In yet other embodiments,the fairing may mount directly to first plate 1300, connector plate 1325or otherwise mount to the arm.

FIG. 14 depicts another embodiment of a mounting bracket used with anarm, such as arm 610. In the embodiment of FIG. 14, an adapter mayinclude one or more of a front or rear lateral extensions 1410. Thelateral extensions include spaced openings to align with multiple spacedslots 668 so that the lateral plates can be coupled to arm 610 using thesame connection members as the mud flap. The lateral extensions may bespaced to fit between the lateral mud flap mounting members that providemud flap mounting openings or may be spaced to fit outside the mud flapmounting members. The outer edge of lateral extensions 1410 may bewelded or otherwise coupled to mounting bracket 1420. Mounting bracket1420 may have a pattern of fairing mounting openings that allow afairing to mount to mounting bracket 1420 in various positions.

FIG. 15 depicts another embodiment of mud flap hanger assembly 1500comprising an arm 1510 that mounts to a vehicle at a proximate end andto a fairing 1505 at a distal end. Arm 1510 may be a fixed length arm ora variable length arm and may be a deflectable or non-deflectable arm.Arm 1510 comprises a mud flap mounting area having a set of spaced slots1530 used to mount a mud flap. A fairing mounting adapter may includefront and rear mounting brackets 1520 having lateral extensions 1550 andend flanges 1555. Lateral plates may include spaced openings that alignwith spaced slots 1530 to allow the mounting brackets 1520 to be mountedto arm 1510 using the same connection members (such as bolts 1570 withnuts 1575 or other connection members) as mud flap 1512. The lateralextensions may fit to the inside or outside of the mud flap mountingmembers that provide the mud flap mounting holes. End flanges 1555define fairing mounting holes 1525 that align with fairing holes 1585 toallow fairing 1505 to be mounted to the mounting brackets 1520. In someembodiments, the holes may be defined so that fairing 1505 may mount inmultiple rotational, horizontal or vertical positions.

FIG. 16 depicts a view of another embodiment of a mud flap hangerassembly 1600 comprising an arm 1610 that mounts to a vehicle atproximate end and supports a fairing 1605 at a distal end. The arm 1610may also support a mud flap 1612. Arm 1610 may be a variable length orfixed length arm and may be deflectable or non-deflectable.

Fairing 1605 couples to arm 1610 at an adapter 1615. In the embodimentdepicted, adapter 1615 comprises a post 1620 that can be received in acorresponding post opening provide by arm 1610 and an end plate 1625coupled to the post. Post 1620 and arm 1610 may include correspondingopenings (e.g., holes 1630 and adapter mounting holes 1635) so that aconnection member, such as bolt, or other connection member may be usedto secure adapter 1615. As can be seen, post 1620 may include multiplespaced openings so that the lateral position of end plate 1625 may beadjusted. End plate 1625 may include a pattern of fairing mounting holesto allow fairing 1605 to be mounted in multiple positions.

FIG. 17 depicts another embodiment of mud flap hanger assembly 1700comprising an arm 1710 that mounts to a vehicle at a proximate end andto a fairing 1705 at a distal end and FIG. 18 depicts a view of anadapter 1720. Arm 1710 may be a fixed length arm or a variable lengtharm and may be a deflectable or non-deflectable arm. As depicted, arm1710 is a bent arm that extends lateral and then bends downward. Arm1710 may bend down a desired amount, including but not limited to anangle between 5-45 degrees and preferably between 5-15 degrees. In otherembodiments, arm 1710 but may be a straight arm or may bend more than 45degrees.

Arm 1710 comprises a mud flap mounting area having a set of spaced slotsused to mount a mud flap. An adapter 1720 may include lateral plate 1725having an upper edge that generally conforms to the shape of arm 1710.Lateral plate 1725 may include spaced openings that align with spacedslots to allow the adapter 1720 to be mounted to arm 1710 using the sameconnection members (such as bolts or other connection members) as mudflap 1712. Lateral plates 1725 may be spaced to be to the inside of orto the outside of the mud flap mounting members that provide themounting holes of the mud flap.

Lateral plate 1725 is coupled to an adapter plate 1730. According to oneembodiment, adapter plate 1730 can have longitudinally aligned inboardand outboard surface or may be aligned at an angle to the longitudinal.Mounting plate can define a set of fairing mounting holes to allowfairing 1705 to be mounted in multiple vertical, horizontal orrotational positions. As shown in FIG. 18, adapter plate 1730 mayinclude multiple rows of fairing mounting holes, in this case slots,where the holes allow for horizontal positioning and the rows allows ofvertical positioning.

FIG. 19 depicts another embodiment of a mud flap hanger assembly 1900comprising an arm 1910 that mounts to a vehicle at a proximate end andto a fairing 1905 at a distal end. FIG. 20 depicts a view of a fairingmounting adapter 1920. FIG. 21 depicts a view of fairing 1905 mounted toarm 1910. Arm 1910 may be a fixed length arm or a variable length armand may be a deflectable or non-deflectable arm. As depicted, arm 1910is a bent arm, but it may also be straight arm. Arm 1910 comprises a mudflap mounting area having a set of spaced slots used to mount a mud flap1912.

An adapter 1920 may include an adapter plate having adapter mountingopenings 2000 through a base portion 2005. Connection member 2105 may beused to mount the bracket to the end of arm 1910. Adapter 1920 mayfurther comprise a set of fairing mounting flanges 2010 having a set offairing mounting openings 2015 that allow fairing 1905 to be mountedusing connection members 1930. As shown in FIG. 21, the fairing mountingflanges 2010 may be offset different distances from base portion 2005and may be angled to allow the fairing 1905 to mount at a desiredlongitudinal angle, including, but not limited to 0-45 degrees from thelongitudinal and preferably 5-15 degrees from the forward direction oftravel when viewed from above. The pattern of fairing mounting holes2015 allows fairing 1905 to be mounted in multiple vertical positions.

As discussed above, a fairing may be coupled to the end of an arm, insome cases using an adapter. Because the fairing may be made out of aplastic or rubber, in some embodiments, it may be beneficial to provideadditional structure support to the fairing at the mounting point sothat, for example, the mounting hardware does not tear a hole in theplastic through repeated dynamic loading. Furthermore, a vehicle may beused in climates in which ice or mud is expected to build up on afairing adding stress to the mounting hardware. To address thesepossibilities and others, a plate or bar of more rigid material, such asa metal, may be coupled to the fairing to provide additional support.The mounting hardware, such as bolts, may be received by or through thesupport member so that the support member alleviates stress from lessrigid components. FIG. 22 and FIG. 23 depict views of one embodiment ofa support plate 2200 used in conjunction with fairing 105. Support plate2200 may be any suitable shape or form factor. A set of posts 2203 mayextend inboard from the inboard side of the support plate that can alignwith and, in some embodiments, be at least partially received in fairingmounting openings in a mounting adapter. In one embodiment, posts 2203may provide fairing holes and be threaded to allow a bolt or otherconnection member to pass through fairing 105 for attachment to thebracket (e.g., to receive connection members 185 as illustrated in FIG.6). In other embodiments, the support member may simply comprise holesthrough which the mounting hardware passes.

Support plate 2200 may be coupled to a fairing 105 in any suitablemanner. In some embodiments, support plate 2200 may be formed first andthen fairing 105 injection molded around support plate 2200, such as byplacing support plate 2200 in a mold and injection molding the fairingusing the mold. FIG. 23 depicts a partial view of one embodiment offairing 105 with support plate 2200 formed therein. Openings 2205 canprovide areas for the polymer to flow during the injection moldingprocess creating a stronger coupling between support plate 2200 andfairing 105.

As noted above, a support arm may be deflectable relative to a vehicle.In other embodiments the fairing support may be deflectable. FIGS. 24-27illustrate various embodiments of arms in which one or both of thesupport arm or fairing a deflectable through a spring attachment. Thesupport arms of FIGS. 24-27 may be fixed length support arms or variablelength support arms.

FIGS. 24A and 24B depict one embodiment of a mud flap hanger assembly2400 comprising an arm 2410 that couples to vehicle at a proximate endand to a fairing 2405 at a distal end. According to one embodiment,assembly 2400 includes a base 2430 with an anchor member 2435 to which aspring 2450 is hooked. The other end of spring 2450 may be hooked toanother anchor member 2460. Base 2430 may be similar to the basesdescribed above to allow deflection of arm 2410 relative to the vehicle.

Similarly, adapter 2420 may include an anchor member 2425, such as aU-bolt, an eye bolt or other anchor member. Connection members 2470 maycouple mounting adapter 2420 to fairing 2405. An outer end plate 2415may also be used to provide additional support around connection members2470. In one embodiment, the connection members 2470 and anchor member2425 may be portions of the same component, such as U-bolt, an eye boltor other component, or may be separate. A spring 2455 is hooked toanchor member 2425 and anchor member 2460. In this example, mountingadapter 2420 is not rigidly connected to arm 2410, but is held againstarm 2410 by the tension force of spring 2455. Thus, mounting adapter2420 and fairing 2405 may deflect relative to arm 2410 (e.g., toposition 2475 or other position illustrated in FIG. 24A). Whileillustrated in conjunction with a specific embodiment, the skilledartisan would recognize that spring attachment to a deflectable fairingcan be incorporated with other embodiments of arms, such as thosedescribed previously and below.

FIG. 25 depicts another embodiment of a mud flap hanger assembly 2500comprising an arm 2510 that couples to vehicle at a proximate end and toa fairing 2505 at a distal end. According to one embodiment, assembly2500 includes a base 2530 having an anchor member 2535. Arm 2510 is notrigidly mounted to base 2530, but is held against base 2530 throughtension provided by spring 2550 or other tension member and, asdiscussed above, may deflect relative to the vehicle. Similarly,mounting adapter 2520 may include an anchor member 2525. Mountingadapter 2520 is not rigidly connected to arm 2510, but is held againstarm 2510 by the tension force of spring 2550 or other tension membercoupled to anchor member 2535 and anchor member 2525. Consequently,fairing 2505 may deflect relative arm 2510 as the spring 2550 stretchesunder sufficient force.

FIG. 26 depicts one embodiment of a mud flap hanger assembly 2600comprising an arm 2610 that couples to vehicle at a proximate end and toa fairing 2605 at a distal end. According to one embodiment, assembly2600 includes a base 2630 that mounts to the vehicle. Arm 2610 may befixed relative to the vehicle. Mounting adapter 2620 may include ananchor member 2625, such as a U-bolt, an eye bolt or other anchormember. Mounting adapter 2620 is not rigidly connected to arm 2610, butis held against arm 2610 by the tension force of spring 2650 or othertension member coupled to anchor member 2625 and an anchor member 2640.Consequently, fairing 2605 may deflect relative to arm 2610 undersufficient force. Spring 2650, however, biases arm fairing 2605 back toan original position.

While several embodiments above have been discussed in terms of mountingfairings in conjunction with a mud flap, other embodiments may be usedto mount fairings without accommodating mud flaps. Some embodiments ofsuch arms may be similar to those previously described, but lackfeatures for mounting mud flaps. FIG. 27, for example illustrates oneembodiment of an assembly 2700 having an arm 2710 that mounts to avehicle at a proximate end and supports a fairing 2705, such as a middlefairing, as discussed below, at a distal end. Arm 2710, in this example,is similar to arm 2410, but lacks features to mount a mud flap.

FIG. 28 illustrates another embodiment of a mud flap fairing assemblycomprising an arm 2810 which may be deflectable or not deflectable andmay have an adjustable length or may have a fixed length. Arm 2810 mayinclude spaced slots 2807 to accommodate mounting mud flap 2815. In theembodiment of FIG. 28, a mud flap 2815 comprises a mud flap section 2820that extends laterally a length along arm 2810 and vertically down fromarm 2810 to create a relatively rectangular cross-section from thedirection of travel. Mud flap 2815 further comprises an integratedfairing section 2825 that bends rearward relative to the direction oftravel. Integrated fairing section 2825 may bend slightly outward suchthat the leading edge is more inboard than the trailing edge 2830 ofintegrated fairing section 2825. The leading edge may be formed by thepoint in the transition to mud flap section 2820 where airflow mayattach to the outer surface of fairing section 2825. FIG. 29 illustratesmud flap 2815 with braces 2905 running from a surface of mud flapsection 2820 to the inner surface of fairing section 2825 to providestructural support and prevent flapping.

FIG. 30 depicts a portion of a tractor-trailer combination vehicle 3000that comprises a tractor or truck 3005 and a trailer 3010. The framerails 3015 of the tractor typically extend rearward below a portion ofthe trailer 3010. There may be one or more axles (i.e., a single axle ortandem axles) with two or four wheels per axle. The embodiment depictedis a tandem axle tractor with front drive axle (or forward tandem axle)tires 3025 and rear drive axle (or rear tandem axle) tires 3020. In theembodiment illustrated, a fairing 105 is mounted behind the rearmost setof tires 3020 in an area overhung by trailer 3010. Fairing 105 can besized and mounted so that a gap 3030 exists between the top of fairing105 and the bottom of trailer 3010 and a gap 3035 exists between thebottom of fairing 105 and the ground. Additionally, a gap 3040 may existbetween the trailing edge of the tire and the leading edge of fairing105. The gaps may have any size depending on where the fairing ismounted. Preferably, the gaps are less than 10 inches each. However, thegaps may be larger or smaller in size and may vary depending on theheight of the 5th wheel, type of truck, road or suspension.

Embodiments of a rear mud flap fairing may be mounted on a vehicleaccording to one or more considerations, such as ground clearance,trailer clearance, etc. In some embodiments, the position or orientationof fairing 105 relative to tires 3020, trailer 3010 or the ground may bebased on the mounting position selected for the support arm on the truckand the mounting position of the fairing to the support arm. Fairing 105may be mounted close to tires 3020 or farther away, may be mounted suchthat a lower edge is some distance above the ground or top edge is somedistance below a trailer, may be angled relative to the ground or thetrailer, etc. According to one embodiment, the leading edge 1210 fairing105 can correspond to the shape of the adjacent tire (e.g., the reartandem tire 3020) and may be mounted such that the distance D betweenfairing 105 and tires 3020 is substantially constant along a selectedarc length when centerline 3050 of fairing 105 generally points to thecenter (hub) 3055 of tires 3020. According to one embodiment, theselected arc length comprises the majority or entirety of leading edge1210.

In some embodiments, the vertical angle of trailing edge 1220 of fairingcan be ±5 degrees of a typical trailer landing gear front edge 3075.Selecting an angle as described may be more aesthetically pleasing.Also, the mud flap fairing angle may be selected such that if the mudflap fairing comes into contact with a trailer landing gear assembly themud flap fairing may be less likely to receive damage. Further, properlyselecting an angle for the mud flap fairing edge (which in thisparticular embodiment is approximately equal to the angle of the fairingin relation to the ground) can be aerodynamically advantageousbecause 1) airflow (including mist or other debris) may also be directeddownward according to the angle of the fairing or fairing edges, and 2).Certain angles may allow for the use of increased surface area on thefairing (or for the fairing to extend further rearward) while minimizingrisk of damage. While ±5 is provided for example, the trailing edge 1220may be arranged at other angles including vertically or otherwise.

The outward position of fairing 105 may be controlled by selecting afixed length arm of the desired length, adjusting the length of anadjustable length arm, offsetting the arm from the frame, selecting thethickness of fairing 105 to ensure proper positioning and configurationof fairing 105, selecting the position of an adapter (such as adapter1615 of FIG. 16) or otherwise controlling the position of the fairing.FIGS. 31A-31C depict top views of a mud flap fairing assembly installedon a truck, illustrating the flow of air when fairing 105 is adjustedtoo far inboard (FIG. 31A), too far outboard (FIG. 31B) and properlypositioned (FIG. 31C). In a preferred embodiment, fairing 105 isconfigured to have leading edge 1210 positioned inboard of outer edge3105 and outboard of tread 3110 of tire 3020. However, a fairingadjusted to other positions that are too far inboard or too far outboardmay still provide benefits over not having fairing 105 at all.

While the embodiment of fairing 105 of FIGS. 31A-C is configured to“kick-out” air flow by directing airflow to the rear and outward, otherembodiments of fairings may produce other air flow patterns. FIG. 32depicts one embodiment of a fairing 3205 mounted to arm 110 behind tire3020. Fairing 3205 has a flat aerodynamic outer profile between theleading edge 3210 and trailing edge 3215. A substantially flat fairingmay be preferred if there is skirting along the length of the trailer,for example. Fairing 3205 may direct air substantially to the rear.

FIG. 33 depicts one embodiment of mud flap fairing assembly having afairing 3305 mounted to arm 110. Leading edge 3310 of fairing 3305 isproximate to the outer edge of tire 3020. The aerodynamic outer surfaceof fairing 3305 bends inward so that trailing edge 3315 is more inboardthan leading edge 3310 to direct air flow inward. Thus, according to oneembodiment, the fairing can be angled/curved inward to direct airflow tothe rear and inward. This may be preferred if, for example, the traileris configured differently such that the total vehicle aerodynamic dragis reduced if the fairing is angled inward rather than outward. This maybe the case if the trailer suspension has an aerodynamic fairing, forexample.

It can be noted that in the various embodiments discussed the leadingedge of the mud flap fairings may be positioned outboard of the outeredge of a tire. The mud flap fairing may be shaped and sized to overlapthe tire when the vehicle is viewed from the side (e.g., to partiallycover the tire from the side). Furthermore, while mud flap fairings havebeen generally discussed in terms of mud flap fairings that are outboardof the mud flap, mud flap fairings may be in board of a mud flap. Insome cases, multiple fairings may be used with the same mud flap, suchas a fairing inboard of the mud flap and a fairing outboard of the mudflap with the fairings mounted to the same support arm. In addition, insome embodiments, adapters may be integrated with the fairing. By way ofexample, an adapter to mount to an end plate or to mud flap mounts maybe molded as a portion of a fairing.

Furthermore, it may be noted mud flap fairings can be supported by anysuitable mud flap hanger arm. While the embodiments of mud flap fairingassemblies discussed above were described in terms of mud flap fairingassemblies that utilize arms that extend generally laterally from theframe or other support structure of a vehicle, embodiments may also beutilized to mount fairings to other styles of mud flap hangers. Forexample, some mud flap hanger systems utilize a bar that is positionedbehind a truck and extends laterally behind the truck to both sides ofthe truck. Mud flaps are mounted to the bottom of the bar near each endof the bar (e.g., mud flaps positioned behind the right and left sets oftires are mounted to the same bar). Embodiments described herein may beutilized with such systems to mount fairings to the ends of the bar.Furthermore, sleeves may be provided at the ends of the bar so that theposition of the fairings may be adjusted.

In some embodiments, an arm base may include an adapter bracket thatmounts to the vehicle. The adapter bracket may have a pattern of holessuch that the arm can be mounted to the vehicle in a number of positions(horizontal, vertical or rotational). In some cases, the position of thefairing may be selected by selecting the position of the arm.

Other embodiments may reduce aerodynamic drag by placing fairings inother locations, such as between tires 3025 and 3020 of FIG. 30. To thisend, a middle fairing assembly may mount to the vehicle frame and spanbetween tires on a front tandem axle and tires on a rear tandem axle. Amiddle fairing may ensure air flow stays outboard of the tires on therear axle (i.e., may reduce or prevent air flow from entering the spacebetween the front axle tires and the rear axle tires). The middlefairing may also contain other aerodynamic features such as vents, ribs,etc., for reducing drag and controlling splash and spray, or providingventilation for dissipating heat.

The shape of the middle fairing may be selected to provide severaladvantages, including but not limited to: the greatest surface area foroptimal aerodynamics; clearance with wheels to prevent rubbing/damage;clearance from top (trailer contact) to prevent damage; clearance frombottom/road (ground contact) to prevent damage; universal fit (differenttrucks have different wheel sizes/spacing, frame heights, etc.); obtaincertain rigidity or structure, especially to provide increased rigidityin areas of the middle fairing that are used for mounting or that areunlikely to come into contact with the wheels, trailer, or ground, forexample. Additionally, the shape can be selected to provide increasedflexibility and resiliency in areas that are likely to come into contactwith the wheels, trailer, or ground, for example; and aesthetics—curvedand sized for use by itself and in combination with any of the mud flapfairing, aerodynamic quarter, and wheel covers.

According to one embodiment, the middle fairing can be attached to asupport arm. The support arm may be coupled to a mounting bracket havingmultiple holes that allow for horizontal and telescopic adjustabilityand improved universality of fit. The array of holes can be used toattach the support arm to a fifth wheel rail with fasteners. A fairingadapter plate can also be coupled to the support arm. The fairingadapter plate can have multiple holes to allow for horizontal, verticalor rotational adjustment of the middle fairing.

The support arm, according to one embodiment, is angled. Angled supportarms may provide advantages to an aerodynamic system. For example, anangled support arm may support the middle fairing closer to the centerof the part to provide improved rigidity without the need for anadditional support or angle bracket. An angled support arm may alsoprevent someone from standing thereon or prevent build-up of snow andice, for example, which adds unwanted weight to the assembly.

FIGS. 34A-34C depict one embodiment of a middle fairing assembly 3400comprising a middle fender support arm 3410 that mounts to the vehicleat a proximate end and to a middle fairing 3405 at a distal end. Supportarm 3410 may couple to a vehicle frame rail at base bracket 3415 andfender 3405 at adapter plate 3417.

Bracket 3415 can comprise an arm mount portion 3420 that is generallyparallel to arm 3410 and a frame rail mount portion 3425 that is angleda desired angle relative to first portion 3420. Bracket 3415 may becoupled to the frame rail of the vehicle in a desired position throughwelding, using connection members or according to another connectionmechanism. Arm 3410 may be connected to bracket 3415 using connectionmembers 3430 passing through holes in portion 3420 and correspondingholes in arm 3410, welding or other connection mechanism. Because of thedifference in angle of arm mount portion 3420 and frame rail mountportion 3425, arm 3410 may extend laterally outward and be angleddownward from the frame rail discouraging standing on arm 3410 andpotentially reducing the accumulation of snow and mud. In otherembodiments, arm 3410 may extend parallel to the ground.

The tolerances, sizes, spacing and number of openings in bracket 3415and arm 3410 may determine how much adjustability there is forpositioning a middle fairing. For example, the tolerances of openingsmay allow the distal end of arm 3410 (i.e., the end coupled to fender3405) to advance or lag a desired distance and may allow a fairing tocant in or out to direct airflow in a desired direction. Thisadjustability allows embodiments to accommodate different size wheels,different vehicle parameters, different driving conditions, and thelike.

The distal end of arm 3410 can be coupled to fender 3405. According toone embodiment, arm 3410 includes a fixed end plate 3440. End plate 3440may be angled relative to a long axis of the main body of arm 3410 sothat the outboard surface of end plate 3440 is generally verticallyaligned in a longitudinal plane or an angle to the longitudinal. Endplate may have openings that can receive connection members 3450. Theopening may be threaded or non-treaded. According to one embodiment,nuts may be welded or otherwise attached to the inboard side of endplate 3440 to provide threads.

According to one embodiment, an adapter plate 3417 may be longitudinallyaligned or aligned at an angle to the longitudinal. Adapter plate 3417may define pattern of holes to receive connection members 3450 formounting adapter plate 3417 to end plate 3440 in one of severalpositions. By selecting the position of adapter plate 3417, the mountingposition of fender 3405 may be selected. Adapter plate 3417 may furtherinclude fairing mounting holes to receive connection members 3455securing fairing 3405 to adapter plate 3417.

The outboard surface of fender 3405 may form an aerodynamic surfacebetween a leading edge 3480 and a trailing edge 3485 that promotesattached rearward flow (when the vehicle is moving forward). In somecases, the outer surface may direct the flow rearward or rearward andslightly inward or outward. The outer surface may have a variety ofprofiles including flat, curved outward toward the rear, or otherprofile. In FIG. 34B, fender 3405 comprises a middle portion 3460, alower portion 3470 and an upper portion 3475. Middle portion 3460provides a mounting area for fender 3405 and can include features 3465,such as ribs or other features, to increase the rigidity of fender 3405around the mounting area. The outboard surfaces of one or more of theupper and lower portions may be in the same plane as, inset from or bemore outboard from the outboard surface of middle portion 3460. Theupper and lower portions may be more flexible than the middle portion toabsorb impacts from the ground or trailer.

In some embodiments, fender 3405 may be symmetric for use on either sideof a vehicle. In some embodiments, fender 3405 may be sized similar tofairing 105, may have a leading edge profile similar to leading edge offairing 105, or may otherwise be manufactured to have a designcomplementary to fairing 105. According to one embodiment, leading edge3480 may be curved to substantially conform to the shape of a tireforward of fender 3405 and trailing edge 3485 may have a curved shape toconform to the shape of tire to the rear of fender 3405.

FIG. 35 illustrates one embodiment of an assembly 3400 mounted to theframe rail (including, but not limited to, the outboard 5th wheel rail)3500 of a truck. Connection members 3505 may pass through openings inthe frame rail and complementary openings in the frame rail mountportion 3425 (see FIG. 34A) of bracket 3415 to mount bracket 3415 to theframe rail. The position of the bracket may be selected so that thedistance between arm 3410 or fender 3405 with respect to the adjacenttires may be selected. Furthermore, the holes used to mount the arm maybe selected to adjust the lateral position of the arm 3410 and, hence,fender 3405.

FIGS. 36A-36B depict views of one embodiment of bracket 3415. Asillustrated in FIG. 36A, arm mount portion 3420 may have a surfacealigned in a first plane and frame rail mount portion 3425 may have asurface aligned in a second plane a selected angle from the first plane.In some embodiments, the angle between frame rail mount portion 3425 andarm mount portion 3420 may be between 15-25 degrees, though in somecases the angle may be 0-15 degrees and in other cases greater than 25degrees. A pattern of rail mounting holes 3600 may be defined throughsecond portion 3425 perpendicular to the second plane and a pattern ofarm mounting holes 3605 may be defined through arm mount portion 3420perpendicular to the first plane. Thus, bracket 3415 may be used tomount an arm to the frame rail in a desired position and at an angle.According to one embodiment, bracket 3415 may be formed of a singlesheet of material (e.g., steel) bent at desired angles. In otherembodiments, bracket 3415 may be formed of other materials and maycomprise multiple pieces.

A fairing may be attached to an arm directly or may use an adapter platefor additional rigidity or adjustability. FIG. 37 illustrates oneembodiment of an adapter plate 3417. Adapter plate 3417 may comprise agenerally flat plate of material, such as steel, having a pattern offairing mounting holes 3705 configured to align with openings in thefairing. According to one embodiment, nuts may be welded or otherwisejoined to the inboard side of adapter plate 3417 to provide threads forthe fairing mounting holes 3705. Adapter plate 3417 may also includepattern of adapter mounting holes 3700 configured to align with openingsin end plate 3440. Pattern of holes 3700 can allow the vertical positionof the adapter plate 3417, and hence the fairing, to be selected.

The tolerances, sizes, spacing and number of openings may determine howmuch adjustability there is for positioning a middle fairing. Forexample, the tolerances of the openings may allow a fender to be rotateda few degrees about an axis normal to the vehicle frame or allow afairing to be angled outward (i.e. a top edge outboard of a lower edgeor a leading edge outboard of a trailing edge, etc.). This adjustabilityallows embodiments to accommodate different size wheels, differentvehicle parameters, different driving conditions, and the like.

In the embodiment of FIG. 34, the support arm is non-deflectable and hasa fixed length. In other embodiments the support arm may be deflectableor have an adjustable length. FIG. 38 illustrates one embodiment afairing assembly 3800 for supporting a fender 3805 with a deflectablearm 3810 and FIG. 39 illustrates one embodiment of arm 3810 and base3820. Arm 3810 may attach to a base bracket with a spring mountedconnection similar to those discussed above in conjunction with mud flaphanger arms.

In FIGS. 38 and 39, a proximate end for coupling to a vehicle frame railmay comprise a base bracket 3815 with rail mounting openings 3817 on anupper portion 3819 for coupling to the frame rail. Base bracket 3815 mayfurther comprise a lower section 3814 for coupling to middle fairingbase 3820. According to one embodiment, upper section 3819 may have agenerally horizontal top and bottom surfaces and lower portion 3814 mayhave generally vertical inboard and outboard surfaces.

Arm 3810 may be coupled to bracket 3815 in a manner that allowsdeflection, such as described above. Base 3820 may be coupled to bracket3815 and may limit the forward and backward deflection of arm 3810(which may be adjustable lengthwise), such as by front and rear flanges3822 extending outward from an inboard wall to the front and back of arm3810.

FIG. 39 depicts a perspective view of an alternate embodiment in whichthe vertical deflection of arm 3810 may be limited by pins or otherhardware 3830. Those skilled in the art will appreciate that flanges3822 may form front and rear limits and hardware 3830 running betweenflanges 3822 above and below arm 3810 may limit vertical deflection.FIG. 39 further depicts an adapter 3900 having a post 3905 that isinserted in a sleeve formed by arm 3810. Adapter 3900 may be coupled toarm 3810 using a connection member, welding or through other connectionmechanism. In some embodiments the angle and lateral position of theadapter may be selected. The adapter may include a mounting plate 3910coupled to post 3905 having a generally vertical outboard face and apattern of holes used to mount a fairing. The pattern of fairingmounting holes can allow a fairing to be mounted in a variety ofpositions.

FIG. 40 depicts a perspective view of an alternate embodiment in whichflanges 3822 are formed on the front and rear sides only to limit thedeflection, whereas flanges 4005 of base 3820 are formed to contact arm2810 on the top (or bottom) and provide a spring constant to bias arm ina desired direction.

FIGS. 41A-41D and FIGS. 42A-42C depict views of alternate embodiments ofan arm and fairing assembly respectively. Arm 4100 may include a jointportion that receives a pin or post extending at least partially betweenan upper extension 4117 to a lower extension 4119 of base 4120. The pinprovides an axis of rotation for arm 4100. Arm 4100 and base 4120 mayform a joint that allows arm 4100 to rotate about the axis of rotationprovided by base 4120. An internal spring or other biasing mechanism maybias arm 4100 to neutral position. Base 4120 can mount to the frame railthrough connection members 4122 or other mechanism. Arm 4100, in someembodiments, may provide mud flap mounts such as a row of holes orslots.

Distal end of arm 4100 may be coupled to an adapter 4110 (as an integralpart or separate adapter) for mounting a fairing. In one embodiment,adapter 4110 provides a plate having a flat outboard surface withthrough holes to allow attachment of a fairing using connection memberssuch that the fairing may be attached in multiple positions.

In another embodiment, as illustrated in FIG. 42C, the fender 4210 mayinclude features 4220 to snap over or receive adapter 4110 to provideattachment in conjunction with or instead of using connection members orto provide structural rigidity proximate to the mounting point. Thefender 4210 may include an outer aerodynamic surface between a leadingedge 4240 and a trailing edge 4245. The outer aerodynamic surfacecomprises a portion 4230 that extends generally longitudinally and aportion 4235 that curves inward such that the trailing edge is outboardrelative to the leading edge. Attached flow can thus be directed backand outward.

As noted above, fairings may increase the aerodynamics of a vehicle bydirecting air flow as needed to flow around wheels or components toimprove aerodynamic efficiency or stability in large vehicles. FIGS. 43Aand 43B depict top views of simulations of air flows around vehiclesshowing streamlines at approximately the height of the center of thewheels of the truck with a yaw angle of two degrees. FIG. 43A depictsairflow around a vehicle that does not have a fairing 105, showing abaseline wake. FIG. 43B depicts airflow around a vehicle having oneembodiment of fairing 105. The differences between the two computersimulation images illustrate reduced drag effect possible due toembodiments of a mud flap hanger with a fairing 105. It should beapparent that the wake created by embodiments such as these disclosedherein may be significantly smaller than the baseline, providing morestable air flow, reduced fuel usage, reduced splash/spray, improvedcooling airflow, or other advantages.

In some cases, multiple fairings and other aerodynamic components may beused in conjunction with each other. FIG. 44 depicts one embodiment ofan aerodynamic system installed on a tractor having rear tandem wheelscomprising a forward set of wheels and a rear set of wheels. Theaerodynamic system can comprise a rear mud flap fairing assembly havinga first fairing 4405, a middle fairing assembly having a second fairing4410, a quarter fender panel 4415 and aerodynamic wheel covers 4420. Therear mud flap fairing assembly can comprise a first arm mounted thevehicle and can comprise any suitable fixed arm, deflectable arm oradjustable length arm. The middle fairing assembly can comprise anysuitable fixed arm, deflectable arm or adjustable length arm. The firstfairing may be configured to direct airflow in a rearward angle (e.g.,rearward, rearward and out, rearward and in) and the second fairing maycomprise a second fairing outer surface configured to direct airflow ina second rearward angle or in other preferred manner. The first andsecond rearward angles may be the same or different. For example, asecond fairing 4410 such as depicted in FIG. 34B may direct flowrearward while a first fairing 4405 such as depicted in FIG. 12 maydirect flow rearward and outward.

A standard quarter fender in a standard location is shown installed inthe figures. An aerodynamic quarter fender fairing may also be used withthe aerodynamic system (instead of or in addition to the standardquarter fender). Examples of aerodynamic quarter fender fairings aredescribed in U.S. patent application Ser. No. 13/452,249, entitled“Aerodynamic Quarter Fender Assembly and Construction Method,” byinventors Joshua Butler, et al., which is fully incorporated as part ofthis disclosure for all purposes. Wheel covers 4420 may provide asubstantially smooth surface flush with an outer sidewall of tires 4440and 4445 or may provide another aerodynamic profile. Examples ofaerodynamic wheel covers are described in U.S. patent application Ser.No. 13/545,100, entitled “Aerodynamic Wheel Covers and MountingAssemblies,” by inventors Joshua Butler, et al., which is fullyincorporated as part of this disclosure.

In operation, airflow may be directed around forward tandem tires 4440by a quarter fender fairing, pass by a first tire 4440, pass by middlefairing panel 4410, pass by a rear tandem tire 4445 and pass mud flapfairing 4405 which can facilitate a smooth transition behind wheels4445, may extend the airflow in a direction substantially parallel withthe outer sidewall of tires 4445, or may direct the airflow out (i.e.,away from the frame rail). Additionally, embodiments of an aerodynamicsystem may direct airflow parallel with the ground, in a downwarddirection or an upward direction as desired.

Embodiments may have a variety of dimensions and may be positioned asneeded or desired. The following provides example dimensions andpositions for one embodiment of a tandem axle tractor-trailer system.However, it should be understood that the dimensions provided areprovided by way of example and not limitation and other dimensions maybe used.

-   -   DGT=distance between ground and trailer;    -   DDT=height of top deflectable portion 4450 of middle fairing        4410: 0 inches<DDT<12 inches; DDB=height of bottom deflectable        portion 4455 of middle fairing 4410: 0 inches<DDB<12 inches    -   DW=maximum width of middle fairing 4410: 16 inches<DW<36 inches;    -   DH=height of middle fairing 4410: 16 inches<DH<48 inches or DGT;    -   DT=clearance between top edge of middle fairing 4410 and        trailer: 0 inches<DT<16 inches (DT≈−DDT in some embodiments        whereby the bottom of the trailer may move into the middle        fairing 4410 and deflect the middle fairing, especially the top        deflectable portion of the middle fairing);    -   DG=ground clearance of middle fairing 4410: (0 inches or        −DDB)<DG<12 inches (DG may be less than 0 in some embodiments        whereby the middle fairing or the ground could move and        therefore deflect the middle fairing, especially the bottom        deflectable portion of the middle fairing);    -   D0=offset distance between a tire adjacent to middle fairing        4410 and the leading or trailing edge of middle fairing 4410: 0        inches<D0<10 inches (in some cases, middle fairing 4410 may be        positioned from the center of the vehicle such that D0 may be        negative (the middle fairing may overlap the tire) without        middle fairing touching the tire.    -   D02=offset distance from a tire closest fairing 4405: D02=D0±3″        inches.

FIG. 45 depicts a table illustrating the results of a third party SAEJ1321 Type II Fuel Economy Test for four configurations of aerodynamicsystems on a tractor-trailer: 1) a tractor having aerodynamic wheelcovers; 2) a tractor having a mud flap fairing 105; 3) a tractor havingaerodynamic wheel covers, a middle fairing and mud flap fairing 105; and4) a tractor having aerodynamic wheel covers and mud flap fairing 105and the trailer having wheel covers. An aerodynamic quarter fender wasnot tested in these configurations but may provide increased fuelsavings.

FIG. 46 illustrates another embodiment of an aerodynamic system 4600mounted to the frame rail by arms that may be deflectable ornon-deflectable and may have adjustable lengths or fixed lengths. System4600 may include a rear fairing 4605 outboard of mud flap 4607, a middlefairing 4610 between front tandem wheels 4620 and rear tandem wheels4625 and front fairing 4615 mounted before front tandem wheel 4620. Thefairings may be mounted to frame rail 4630 by arms 4635 which may eachbe the same type of arm or different types of arms. According to oneembodiment, one or more of the arms may be configured to allow the armto deflect relative to the frame rail and the respective fairing todeflect relative to the arm. In other embodiments, one or more of thearms may allow deflection at only one end or be non-deflectable. One ormore of the arms may have a fixed length or adjustable length.

FIG. 47 illustrates another embodiment in which front fairing, middlefairing and rear mud flap fairing are integrated into a single largefairing 4700 that spans the tandem and is supported by arms 4710.According to one embodiment, one or more of the arms may be configuredto allow the arm to deflect relative to the frame rail and therespective fairing to deflect relative to the arm. In other embodiments,one or more of the arms may allow deflection at only one end or benon-deflectable. One or more of the arms may have a fixed length oradjustable length. According to one embodiment, at least one of the armsmay also provide a mud flap mount. The above described configurationsand other configurations are not limited to tandem axle tractorapplications. Any tractor, truck, or trailer with any number of axlesmay benefit by a different combination. For example, a single axletractor might not benefit by a middle fairing but may benefit by anycombination of a mud flap fairing, wheel cover, and aerodynamic quarterfender fairing.

Although the invention has been described with respect to specificembodiments thereof, these embodiments are merely illustrative, and notrestrictive of the invention. The description herein of illustratedembodiments is not intended to be exhaustive or to limit the inventionto the precise forms disclosed herein (and in particular, the inclusionof any particular embodiment, dimensions, feature or function is notintended to limit the scope to such embodiment, feature or function).Rather, the description is intended to describe illustrativeembodiments, features and functions in order to provide a person ofordinary skill in the art context without limiting the invention to anyparticularly described embodiment, feature or function. While specificembodiments and examples are described herein for illustrative purposesonly, various equivalent modifications are possible within the spiritand scope of this disclosure, as those skilled in the relevant art willrecognize and appreciate. As indicated, these modifications may be madein light of the foregoing description of illustrated embodiments and areto be included within the spirit and scope of the invention. Thus, whilethe invention has been described herein with reference to particularembodiments thereof, a latitude of modification, various changes andsubstitutions are intended in the foregoing disclosures, and it will beappreciated that in some instances some features of embodiments of theinvention will be employed without a corresponding use of other featureswithout departing from the scope and spirit of the invention as setforth. Therefore, many modifications may be made to adapt a particularsituation or material to the essential scope and spirit of theinvention.

Reference throughout this specification to “one embodiment,” “anembodiment,” or “a specific embodiment,” or similar terminology meansthat a particular feature, structure, or characteristic described inconnection with the embodiment is included in at least one embodimentand may not necessarily be present in all embodiments. Thus, respectiveappearances of the phrases “in one embodiment,” “in an embodiment,” or“in a specific embodiment,” or similar terminology in various placesthroughout this specification are not necessarily referring to the sameembodiment. Furthermore, the particular features, structures, orcharacteristics of any particular embodiment may be combined in anysuitable manner with one or more other embodiments. It is to beunderstood that other variations and modifications of the embodimentsdescribed and illustrated herein are possible in light of the teachingsherein and are to be considered as part of the spirit and scope of theinvention.

Furthermore, the characterization of any feature as “optional” herein isprovided by example and is not intended to and should not be read toimply that other features not characterized as optional are not alsooptional in various embodiments.

In the description herein, numerous specific details are provided, suchas examples of components and/or methods, to provide a thoroughunderstanding of embodiments of the invention. One skilled in therelevant art will recognize, however, that an embodiment may be able tobe practiced without one or more of the specific details, or with otherapparatus, systems, assemblies, methods, components, materials, parts,and/or the like. In other instances, well-known structures, components,systems, materials, or operations are not specifically shown ordescribed in detail to avoid obscuring aspects of embodiments of theinvention. While the invention may be illustrated by using a particularembodiment, this is not and does not limit the invention to anyparticular embodiment and a person of ordinary skill in the art willrecognize that additional embodiments are readily understandable and area part of this invention.

What is claimed is:
 1. A fairing assembly for a commercial vehicle,comprising: a forward fairing configured to be disposed such that theforward fairing begins inboard of an outer tire tread edge of a tire ofa forward drive wheel and progresses outwards to end outboard of a wallof the tire of the forward drive wheel with respect to a longitudinaldirection of the commercial vehicle; and a rear fairing configured to hedisposed such that the rear fairing begins inboard of an outer tiretread edge of a tire of a rear drive wheel and progresses outwards toend outboard of a wall of the tire of the rear drive wheel with respectto the longitudinal direction of the commercial vehicle, wherein therear fairing has a concave cross-section in a transverse direction ofthe commercial vehicle.
 2. The fairing assembly according to claim 1,wherein the forward fairing and the rear fairing each include arespective first portion made of a first material and a respectivesecond portion adjoining the first portion and wherein the secondportion is made of a second material that is different from the firstmaterial.
 3. The fairing assembly according to claim 2, wherein thefirst material is a first plastic material.
 4. The fairing assemblyaccording to claim 3, wherein the first plastic material is athermoplastic elastomer based on olefin.
 5. The fairing assemblyaccording to claim 2, wherein the second material is a second plasticmaterial.
 6. The fairing assembly according to claim 5, wherein thesecond plastic material is an Ethylene-Propylene-Dien-Monomer rubber. 7.The fairing assembly according to claim 2, wherein the respective firstportion has a higher rigidity than the respective second portion.
 8. Thefairing assembly according to claim 2, wherein the respective secondportion forms a respective edge region of the respective fairing.
 9. Acommercial vehicle, comprising: an axle; and a fairing assemblyaccording to claim
 1. 10. The commercial vehicle according to claim 9,wherein the commercial vehicle is a tractor.
 11. The fairing assemblyaccording to claim 1, wherein a cross-sectional profile of the forwardfairing is cubic.
 12. The fairing assembly according to claim 1, whereina cross-sectional profile of the rear fairing is quadratic.